Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation

ABSTRACT

A composite foam and concrete wall includes a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface. A concrete layer is secured to a surface of the foam layer.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/050,471 entitled COMPOSITE FOAM AND CEMENT WALLAND METHOD OF MAKING SAME that was filed on Sep. 15, 2014, the contentsof which are incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates to a composite foam and concretefoundation and a composite foam and concrete wall and a method ofmounting the wall to the foundation.

Construction of a typical footing is very labor intensive and can take aconsiderable amount of time to construct. The typical structure requiresa hole to be excavated to a desired depth such that a footing can beconstructed that will not be affected by frost or other conditionscreated by the climate. However, in some construction projectsexcavation of the soil is not required. The footing is then typicallyplaced concrete. Once cured, a foundation wall, typically cinder blockssecured with mortar, a cementious wall or a masonary wall is thenconstructed with the footings providing the necessary support for thestructure. Once the foundation wall is cured, soil is backfilled aroundthe foundation wall to provide a desired grade away from the foundation.

However, excavation of the soil, placing the footing, waiting for thefooting to cure, constructing the foundation wall and waiting asufficient time for curing takes a significant amount of time and effortthat increases the cost of construction. It may be beneficial and costeffective to utilize a foam foundation that can be utilized to support afoundation wall, which may or may not be preformed.

A typical wall includes a bottom plate or foundation sill that isattached to a foundation, typically a concrete slab or concrete wall.Bottom ends of spaced apart vertical studs are secured to the bottomplate and a top ends of the spaced apart vertical studs are secured to atop plate. A height of the wall is essentially defined by the length ofthe vertical studs. The wall provides the support for the outer wallmaterial, such as wood panels and siding, and also the interior wallmaterial, such as sheet rock. Insulation is typically placed between thestuds when the stud wall is raised into place and the outer wallmaterial is secured to the stud wall.

Construction of the stud wall is very labor intensive and can take aconsiderable amount of time to construct. The studs must be cut to aprecise length and secured to the bottom and top plates, typically withnails. In the event windows and/or doors are to be placed into the wall,then the studs must be cut to accommodate the required space for thewindow and/or door and the space must be reinforced with a lintel, whichalso must be constructed by the construction workers.

Once the stud wall is formed, it is raised and secured to thefoundation, typically with bolts that are set into the concretefoundation and through bores in the bottom plate. The bores in thebottom plate are positioned about the bolts. Washers are positioned onthe bolts and nuts threadably engage each bolt to frictionally securethe bottom plate to the foundation. Once the stud wall is raised, theouter wall is secured to the studs typically with nails and then sidingis secured to the outer wall.

Electric wiring and plumbing are then installed which may includingdrilling through the studs to place the wiring and plumbing in thedesired locations within the wall. Installation of the electric wiringand plumbing can be very labor intensive, time consuming and costly.

In many developing locations, such as the oil fields of North Dakota,the lack of adequate housing is an issue. While people are willing topay for the construction of a residence, the labor force is notavailable to meet the housing construction needs. The use of a standardwood stud frame for the residence is one of the impediments to havingthe required housing built due to the time required to properly build astructure with stud walls.

Also, while quality lumber is currently available, it is foreseeablethat in the future that the wood required for the stud wall may not beavailable. As such, there is a need for a wall, that does not requirewood, or other renewable materials, which can be quickly constructedwhile having good energy and sound efficiency.

SUMMARY

One aspect of the present disclosure relates to a composite foam andconcrete wall. The composite foam and concrete wall is formed byaligning slabs of foam side by side to form a foam layer where the seamsbetween the foam panels are substantially parallel to the upper andlower edges of the composite wall. Spaced apart channels are formed intoan upper surface of the aligned slabs of foam substantiallyperpendicular to the seams wherein the pilasters are a sufficient depthto aid in securing a concrete layer to the upper surface of the foampanels. A horizontal channel is formed into the foam layer at a topsurface. Rebar is placed in the channels and is raised from the foamsurface a selected distance with rebar chairs. An end plate utilized asa top wall of a form with spaced apart lifting mechanism is positionedproximate the top end of the foam layer and proximate a top edge of thehorizontal channel. A remaining portion of the form is placed about aperimeter of the foam layer and extends upwardly above the foam layer aselected distance, where the distance defines a wythe of concrete of thecomposite wall. Concrete is then placed into the form and over the foamlayer wherein the concrete is placed into the channels and createspilasters that increase the structural strength of the wall and alsoincrease the bond strength between the concrete layer and the foamlayer. When the wall is raised, utilizing the lifting mechanisms withinan upper horizontal pilaster proximate the top portion of the form, thelifting force is substantially perpendicular to the seams in the foamand, therefore, prevents cracking in the concrete during the lift. Whilethe concrete is not set, structural detail can be added to the surface,such as rocks, coloring or a stamping that resembles siding or a brickpattern. Because of the thickness of the concrete, the wall isstructural, meaning it satisfies the requirements of a load bearing walland the foam layer provides superior thermal and sound insulatingqualities.

Another aspect of the present disclosure relates to a composite foam andconcrete foundation. The foundation includes a foam portion that candefine the dimensions of the foundation, including the length, the widthand the height of the foundation. An upper channel is formed into thefoam portion substantially along a longitudinal axis extending along thelength of the block from a top surface and into the block. The upperchannel extends about one half the thickness of the block and can have adovetailed construction such that a width of the bottom of the channelis greater than the opening in the top surface and wherein both left andright side surfaces extend inwardly at an acute angle from the bottomsurface of the channel to the opening. The opposing ends of the foamblock include left and right openings that extend from the top surfaceto the bottom surface where a top portion of the left and right openingsis defined by the upper channel. Lower portions of the left and rightopenings can have a dovetail configuration where an opening at thebottom surface is lower than that of the transition from the uppersurface to the lower surface. Rebar may optionally placed within theupper channel and/or the left and right opening and concrete is thenplaced into the upper channel and the left and right openings such thatthe concrete is substantially even with the outer surfaces of the foamportion. Because of the thickness of the concrete in the upper channel,the composite foam and concrete foundation meets the structuralrequirements of a standard foundation while being able to be producedoff-site or prior to the construction of the structure. In somestructures, piers or pilings may also be used to ensure the structuralrequirements are met.

Another aspect of the present disclosure relates to a method ofconstructing a foundation of structure. The method includes positioninga number of pilings or piers into the soil at locations wherefoundations described above abut each other such that the concretebottom surfaces of the foundation rest on the upper surface of the pier.The piers and foundations are positioned into the soil at a selecteddepth (which is dependent upon building codes) such that the concrete inthe upper surface defines a perimeter of the structure. A structuralwall as described above is positioned proximate the foundation and israised to be positioned on the concrete surface of the foundations wherethe structural wall is disclosed herein and can be a composite foam andconcrete wall. Upper edges of the walls are leveled with shims betweenthe foundation and the wall. Once positioned on the concrete surface ofthe foundation and leveled, the structural wall is then secured to thefoundation by a securing mechanism. Once the walls are secured to thefoundations, the adjacent walls are secured together at the seams withadhesive and additional securing mechanisms can secure the adjacentwalls together at the top surface. The method also includes positioningan insulating panel about a perimeter of the foundations and adjacentthe outside edge of the foundation. The insulating panel extends aselected distance away from the foundation such that the foundation isprotected from climatic factors such as frost. Soil is then back filledover the insulating panel, the foundation and is adjacent a lowerportion of the structural wall.

Another aspect of the present disclosure includes a bracket that isconfigured to be secured to a foam layer at least along a side edge anda top edge of the foam layer. The bracket includes a bottom portionconfigured to be positioned on an upper surface of the foam block and anangled tang forming an acute angle with the bottom portion. The angledtang is configured to be positioned in an angled slot within the foamlayer to prevent the bracket from moving on the foam layer as theconcrete is placed. A wall extends from a distal edge the bottom portionwherein a distance from a top edge of the wall to the bottom portiondefines a thickness of a wythe of concrete, when placed. A screedportion extends from an upper end of the wall where the screed wall issubstantially parallel to the bottom portion. The screed wall provides asurface for leveling the placed concrete. The bracket can optionallyinclude angled spaced apart braces extending from the bottom portion tothe wall wherein the braces can prevent the wall from flexing outwardlydue to forces imparted onto the wall by the placed concrete. In someinstances, the bracket supports one or more lifting mechanism that areencased within the placed concrete where the lifting mechanisms can beutilized to lift the wall into place. An angle of the wall can be anydesired angle relative to the bottom portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a typical gable roofed house.

FIG. 2 is a perspective view of a foam layer and form for a solid walland a wall with a window utilized to form a portion of the house.

FIG. 3 is an end view of the wall.

FIG. 4 is a view of a portion of the wall with a portion of the windowframe with rebar placed within a pilaster.

FIG. 5 is another view of a portion of the wall with a portion of thewindow frame with rebar placed within a pilaster.

FIG. 6 is a view of a portion of the wall with the top, horizontalpilaster and the top plate.

FIG. 7 is another view of the portion of the wall with the top,horizontal pilaster and the top plate.

FIG. 8 is a view of a portion of the window frame and the foam wall.

FIG. 9 is a perspective view of the window frame.

FIG. 10 is a perspective of an installed window frame with the wall.

FIG. 11 is a perspective view of the solid wall having a bottom surfacetreatment and a top surface treatment.

FIG. 12 is another perspective view of the solid wall having a bottomsurface treatment and a top surface treatment.

FIG. 13 is a perspective view of the wall with the window having abottom surface treatment and a top surface treatment.

FIG. 14 is another perspective view of the wall with the window having abottom surface treatment and a top surface treatment.

FIG. 15 is another perspective view of the wall with the window having abottom surface treatment and a top surface treatment.

FIG. 16 is a perspective view of the wall with the window having thewindow being raised with a loader bucket on a tractor.

FIG. 17 is a side view of the raised wall.

FIG. 18 is a perspective view from the top surface of the raised wall.

FIG. 19 is a perspective view of a foundation.

FIG. 20 is a top view of the foundation

FIG. 21 is an end view of the foundation.

FIG. 22 is a bottom view of the foundation.

FIG. 23 is a schematic view of the foundation positioned within the soiland a wall secured thereto.

FIG. 24 is another schematic view of another foundation positionedwithin the soil and a wall secured thereto.

FIG. 25 is a schematic view of foundation forms creating a perimeter ofa structure with piers located where foundations are positioned adjacenteach other.

FIG. 26 is a schematic view of another embodiment of a wall havingbrackets defining edges of the concrete layer.

FIG. 27 is a cross sectional view of the wall illustrated in FIG. 26 .

FIG. 28 is an exploded view of a bracket with a lifting mechanism.

FIG. 28A is a side view of the bracket illustrated in FIG. 28 .

FIG. 29 is a perspective view of a bracket with a right angle.

FIG. 29A is a side view of the bracket illustrated in FIG. 29 .

FIG. 30 is a perspective view of a bracket with a 135 degree angle.

FIG. 30A is a side view of the bracket illustrated in FIG. 30 .

FIG. 31 is a schematic view of a wall joint with an exterior ninetydegree angle.

FIG. 32 is a partial schematic view of two wall secured together.

FIG. 33 is a partial perspective view of a wall with channels in thefoam layer configured to accept rafter or ceiling beams.

FIG. 34 is a flow chart of an exemplary building method.

FIG. 35 is a schematic view of batter boards defining a perimeter of astructure and holes for piers of a structure.

FIG. 36 is a schematic view of holes for piers, foam portions offoundations defining a perimeter of the structure and a drainage gridfor the structure.

FIG. 37 is an enlarged view of a portion of FIG. 36 .

FIG. 38 is a view of a foam portion of a wall constructed with twolayers of foam.

FIG. 39 is perspective view of another foundation with holes within thefoam portion for drainage purposes.

FIG. 40 is a schematic view of a foundation portion of a structure.

FIG. 41 is a flow chart of another exemplary building method.

DETAILED DESCRIPTION

A gabled house is illustrated in FIG. 1 that is constructed usingfoundations, walls and methods of construction as disclosed herein. Aform 10 for a wall 12 without any openings and a form 20 for a wall 22with a window frame 23 are illustrated in FIG. 2 . The form 10 includesa bottom wall 14 and an opposing top wall 16 that are connected with aright sidewall 18 and a left sidewall 19 wherein the left side wall isat an angle which is about 45 degrees. The form 20 includes a bottomplate 24 and an opposing top plate 26 that are connected with left andright walls 28 and 29. The form 20 does not include an angled wall, butone or both sidewalls 28 and 29 could be at any desired angle.

Referring to FIGS. 2-7 , the wall 12 and the wall 22 have a similar foamlayer 46 where the layer 46 includes a plurality of foam panels 40, 42and 44 that are placed adjacent each other such that seams 48 and 50 aresubstantially parallel to a bottom surface 52 and a top surface 54. Theplurality of foam panels 40, 42 and 44 form the foam layer 46 of acomposite load bearing wall 12 and 22. While three foam panels 40, 42,and 44 are illustrated to form the height of the wall, any number ofpanels and any width panels are within the scope of the presentdisclosure.

A typical foam panel is constructed of modified expanded polystyrenebecause the foam has a high R value for insulation purposes. The foamlayer is typically treated with a pesticide such as zinc borate toprevent insect and rodent infestations. The modified expandedpolystyrene foam also is a fire preventative material, as the modifiedfoam material will not promote a fire once the source of the fire isextinguished or removed from the foam. One non-limiting foam material issold under the INSULFOAM® trademark by the Insulfoam division of theCarlisle Construction Materials headquartered in Puyallup, Wash.However, other materials of the foam panels are also contemplated.

As illustrated the foam panels 40, 42 and 44 are nominally about sixinches in thickness. However, a nominal eight inch thickness foam panelis also contemplated. The foam panels can be any desired thicknessprovided the panels provide the necessary insulation and structure tosecure a concrete layer thereto.

The foam layer 46 includes left and right channels 56 and 58 that arecut into the panels 40, 42 and 44 from the bottom surface 52 to the topsurface 54 wherein the left and right channels 56 and 58 aresubstantially perpendicular to the seams 48 and 50. A depth of thepilasters 56 and 58 is nominally about two inches. However, the depth ofthe channels 56 and 58 can be any depth that aids in securing a concretelayer to the foam layer 46 while not adversely affecting the structuralintegrity of the foam layer 46. It is understood that the thickness ofthe foam layer 46 can dictate the depth of the channels 56 and 58.

It is also contemplated that a channel be formed around the entireperimeter of the formed wall which will sheer the entire panel tomaintain the panel's shape and integrity. Also, a bottom header or beamis also contemplated, while not illustrated in the figures.

The foam layer 46 includes a channel 60 at the top surface 54 thatextends into the foam layer 46 at a similar depth as that of thechannels 56 and 58. The channel 60 is substantially the same depth asthat of the channels 56 and 58.

The channels 56, 58 and 60 can be formed by any desired mechanismincluding a chain saw with a depth gauge or a hot melt type of cuttingprocess. Whatever method is utilized, the channels 56, 58 and 60typically are formed with a dovetail construction where a width of thepilaster 56, 58 and 60 is greater at the bottom surface relative to atop surface.

The top plate 26 includes a dove tail cut 62 along the length to provideadditional securing of the concrete layer to the top wall 26. The windowframe 23 includes a dado cut 25 about the outer perimeter to also allowconcrete to flow therein and provide a more secure attachment of theconcrete layer to the window frame 23. However, dado cuts in the topplate 26 and the window frame 23 are optional.

Once the channels 56, 58 and 60 are formed into the foam panel 46, rebarchairs 66 and rebar 68 are placed into the channels 56, 58 and 60. Therebar 68 provides strength to the concrete within the channels 56, 58and 60 and prevents the concrete pilasters placed into the channels fromcracking within the channels 56, 58 and 60.

Referring to FIGS. 8-10 , the window frame 23 is installed by utilizingboards 70 that include the dado cuts 25 and have flashing 72 and 74 atthe top and bottom edges 76 and 78. A gap between the window frame 23and the foam panel 46 allows the concrete to be placed between the frame23 and the foam layer 46. The concrete between the frame 23 and the foampanel 46 forms a tight seal which prevents air infiltration and otherexternal pressures, such as sound, wind, moisture and heat (or cold)from entering into the interior of a build from the exterior and viseversa. The flashing 76 and 78 extends around the perimeter of the windowframe 23 about the outer edges 76 and 78 and aids, in preventing waterand moisture from entering into the seam between the boards 70 and thefoam panel 46 and maintaining a flat interior surface which can be verybeneficial when securing dry wall to the interior surface. However, theflashing 76 and 78 is optional.

While any type of board 73 for the window frame 23 can be utilized, atypical pre-manufactured window frame 23 is manufactured by Prebuck LLClocated in Grand Rapids, Mich. The boards 73 are engineered laminatedstrand lumber (LSL) and are treated to prevent decay and insectinfestation and have a minimal moisture content of about 4-6 weightpercent. The Prebuck engineered boards are made from saplings that aretreated and then processed into the engineered board. As such, thetreatment extends through the entire board and not just penetrating aportion of the board. Therefore, when the board is cut, the end remainstreated and will not decay or be susceptible to insects. The treatmentutilized in the Prebuck engineered board is zinc borate, which is apreservative and prevents insect infestation. Zinc borate is not astoxic to human beings as other wood preservatives.

While the use of LSL is disclosed for window and door frames, it is alsocontemplated that the LSL can also be used for any structural and/orframing members within a building. Suitable LSL structural and/orframing members include those sold under the StrandGuard® tradedesignation and the TimberStrand® trade designation by WeyerhaeuserCompany located in Federal Way, Wash. and the SolidGuard® tradedesignation by Louisiana Pacific Corporation headquartered in Nashville,Tenn. While an engineered wood window frame treated throughout itsthickness with zinc borate is disclosed, any type of material that canbe formed into the window frame is within the scope of the presentinvention. It is also contemplated that a similar manufacturing processbe utilized with door frames. It is also contemplated that the windowsand door frames be constructed of any suitable building material,including but not limited to metal and composite materials.

A typical window would be a vinyl window wherein the perimeter of thewindow casing is secured to the window frame 23 with a bead of sealantsuch as, but not limited to, a caulk. Utilizing a vinyl window frame andcaulk removes the need for flashing as there is no means of penetrationof water or air between the window casing and window frame 23.

Referring to FIGS. 11 and 12 the finished wall 12 with the foam layer 46and a concrete layer 80 is illustrated with the framing removed. Theconcrete layer 80 is at least nominally two inches in thickness whichprovides sufficient structural integrity such that the wall 12 can be anexterior load bearing wall. The concrete layer 80 fills the channels 56,58 and 60 to form pilasters in the foam layer and placed until even witha top of the framing. While the concrete layer 80 is not cured, asurface treatment 82 can be applied to the concrete layer 80. Asillustrated, field stones 84 are set into the concrete layer 80 in alower portion 86. The concrete layer 80 in the lower portion 86 iscolored a different color than the concrete 80 in an upper portion 88.

While field stones 84 and utilizing different colors in the concretelayer 80 are illustrated, these are but a couple of non-limitingexamples of surface treatments that can be utilized. Other non-limitingsurface treatments include stamping the concrete to have the appearanceof siding or brick. Also, paint, dye or other colorant could be appliedor integral to the concrete mix to provide different surface treatment.

Referring to FIGS. 13-15 the finished wall 22 is illustrated with theconcrete layer 80 secured to the foam layer 46. As illustrated fieldstone 84 are positioned into the concrete layer at the lower portion 86as the surface treatment 82. The concrete layer 80 in the lower portion86 is not colored, and an upper portion 88 has a contrasting color. Thewindow frame 78 has been covered by the concrete layer 80 and is notvisible. The concrete layer 80 can have similar treatments as describedwith respect to the wall 12.

Referring to FIGS. 16-18 , the wall 22 is illustrated being liftedutilizing a loader bucket on a tractor where chains 90 are secured tobolts 92 in the top plate 26. It should be understood that the pilasterwithin the channel 60 along the top plate 26 provides additionalstructural integrity to lift the wall 22 relative to a nominal two inchthickness of the concrete layer 80. As the wall 22 is lifted from ahorizontal position to a vertical position, a gravitational force isplaced upon the wall 22 that is substantially perpendicular to the seams48 and 50. As such, the panels 40, 42 and 44 do not move relative toeach other as the wall 22 is lifted, which prevents cracking, bowing orbending of the concrete layer 80 which may not be apparent at the timeof the lift but will become noticeable over time. It should beunderstood that the wall 12 is constructed similarly to the wall 22 andwill also not cause a crack in the concrete layer 80 when lifted.

It is also contemplated that siding fastening strips, such as furringstrip or nailing strip, can be embedded into the concrete layer 80 orhave a portion of the siding fastening strips extend from an exteriorsurface of the concrete layer. The fastening strips can be constructedof wood or metal and are spaced apart to support siding such, forinstance, lap siding. As such, Applicant can customize the look of anexterior surface to meet any needs of the owner including having a stoneor brick treatment on the bottom portion with lap siding on the upperportion of the wall.

The walls 12 and 22 can be manufactured at a plant or manufacturingfacility remote from the site of the construction and therefore caneliminate much of the labor required to build a stud framed structure.The walls 12 and 22 can be prefabricated to any reasonable desiredlength, width and height and can be lifted and installed on a previouslyformed foundation at the site. Because of the thickness of the concretelayer 80 the wall 12 can be installed below ground and can be secured toa foundation for the foundation, such that a foundation wall is notrequired, which can also save time and money compared to a stud framestructure.

Also because the wall 12 and 22 can have beveled side edges such as theside wall 19, two walls can be easily joined together using connectorsthat are positioned into the adjacent concrete layers 80. Since theconnectors would not penetrate though the inner surface of the foam,there would be no thermal bridge from the outside which would affect theinsulating properties of the foam layer 46. A typical angle of thebeveled edge is 45 degrees so that any wall edge can be mated with anyother wall edge. However, other angles of the edges besides 45 degreesare also contemplated. It is also contemplated that the walls 12 and 22can include interlocking joints which aid in secure the walls 12 and/or22 together, typically with a securing mechanism.

Because the foam layer 46 is of a thickness such as for example eightinches, the utilities that are required in the wall can be easilyinstalled by cutting channels into the foam layer 46. It is contemplatedthat a chain saw with a depth guard or a hot knife designed to cut foamcan be utilized to quickly and efficiently form the channels. Once thechannels are formed into the foam layer the utilities including plumbingand electric wiring can be easily installed.

Also, sheet rock can be glued or adhered to the inner surface of thefoam layer 46 so that the building can be quickly finished relative to astructure that utilizes stud walls. When the adhesive is properlyapplied to the foam or sheet rock, the adhesive forms a vapor barrierthat meets code and does not require a plastic wrap. This allows for theelimination of mechanical fastening of the sheet rock by for instancenails or screws, which in turn minimizes the labor required to mount thesheet rock and the finishing of the sheet rock, such as with a mud toevening the seams and cover the nail or screw indentions. Further, noadditional insulation in the walls is necessary because the foam layer46 provides the necessary insulation. As such, the step of installinginsulation which is required in a standard stud wall is not required.

It is also contemplated that a layer of plaster can be applied to thefoam to provide a finished look to the interior walls instead of thesheet rock. The application of plaster is less expensive and less laborintensive than securing sheet rock to the foam layer and then muddingthe seams prior to painting the sheet rock. It is also noted that acolorant can be mixed into the plaster such that a coat of paint may notbe required.

As such, the walls of the structure can be formed off-site and shippedto the location. The bolts 92 or lifting hardware in the top plate 26are designed to easily raise the walls 12 and 22 such that the walls ofthe building can be quickly and efficiently installed relative to thestud wall structure. Finally, the walls can be quickly secured together,with prefabricated window and door frames such that the structure can beefficiently constructed in a short amount of time.

A foundation 100 that can be utilized with the walls 12 and 22 isillustrated in FIGS. 19-22 . The foundation 100 includes a foam block102 (typically EPS) of a desired length L, width W and height H. Thefoam block 102 typically has a height of about twelve (12) inches and awidth of twenty four (24) inches and any desired length. However, thepresent disclosure is not limited a block of having a twelve (12) inchheight and a twenty four (24) inch width. Rather any foam block having asufficient size can be used provided the block of foam provides thenecessary structural integrity.

A dovetail channel 104 (as illustrated in FIGS. 23 and 24 ) is cut intothe block from the top surface 105 and into the block approximately adistance one half of the height where the dovetail channel 104 extendsfrom a left end 106 to a right end 108. A typical depth of the dovetailchannel 104 is about 12 inches. However, other depths are contemplated.

The dovetail channel 104 defines a top portion 108 of a left and rightend channel 110 and 111. The left and right end channels 110 and 111have a dovetail configuration and extend from the top surface 105 to abottom surface 112.

A form is positioned about the foam block 102 and concrete is placed tofill the dovetail channel 104 and the left and right end channels 110.The left and right channels 110 extend into the block 104 a selecteddistance such that a concrete surface 114 and 116 large enough to engagean earth anchor or pier after the concrete is placed and cured.

The end channels 110 are filled with concrete and form concrete verticalpilasters 124 and 126 that include the surfaces 114 and 116 that arecapable of being placed upon a platform of an earth anchor, piling, pieror other support, if necessary. A top surface 123 of the pilaster 122forms a portion of a perimeter of the foundation of the structure thatsupports the walls 12 and/or 22 of the structure

Referring to FIG. 23 , the foundation 100 is illustrated positionedwithin the soil a selected depth below ground level 120. The foundation100 includes the foam block 102 and a concrete pilaster 122 having adovetail cross section and a height that this approximately half of theheight H of the block 104. The dovetail configuration of the pilaster122 within the block aids in retaining the pilaster 122 within the foamblock 104. While dovetail configured channels and pilasters arediscussed and illustrated, any suitable configuration of the channelsand pilasters for the foundation is also contemplated.

Once the foundations 104 are placed in position, insulation panels 130are then place adjacent an outer vertical surface 132 of the foam block104 about the entire perimeter of the structure. The insulation panels130 are typically about 2 inches thick and about 48 inches in width(however other dimensions of the insulating panels are contemplated).The insulation panels, typically EPS foam, prevent frost and otherclimate factors from engaging the foundation and extend the life of thestructure. However, the foundation 100 can be used at a depth that wouldnot require the insulation panels 130.

The wall 12 or 22 can then be lifted onto a top surface 123 of thepilaster 122 and secured thereto with a fastening mechanism. Referringto FIG. 23 , the fastening mechanism 140 includes metal strips 142secured to the top surface 123 of the pilaster 122 and to the sides ofthe wall 12 and/or 22. An angle iron 144 is secured to the metal strips122, typically with a weld. Utilizing the metal strips 142 and the angleiron 144 secures the wall 12 and/or 22 to the foundation 100.

Referring to FIG. 24 , the wall 12 and/or 22 is secured to thefoundation 100 with a securing mechanism that includes a channel 150within the upper surface 123 of the pilaster 122 that is sized to awidth and depth to accept a bottom portion of the wall 12 and/or 22. Aconcrete or adhesive can be used to secure the wall 12 and/or 22 withthe channel 150 and thereby secure the wall 12 and/or 22 to thefoundation 100 in a vertical position.

While a channel and concrete attaching mechanism and a weld betweenmetal strips 142 with an angle iron 144 are illustrated, other securingmechanisms are also within the scope of the present disclosure.

The use of the disclosed foundation 100 and the walls 12 and/or 14eliminates the need to dig and place footings and to build a foundationwall, typically out of cinder blocks. Therefore, a significant amount oftime and expense can be eliminated from the construction of a structureutilizing the disclosed foundation 100 and walls 12 and/or 14.

FIG. 25 schematically illustrates adjacent foundations 100 forming afootprint or perimeter of a structure wherein piers 101 are locatedunder the adjacent ends of the foundations 100. A non-limiting exampleof a pier includes a bell shaped pier. A insulating layer 103 abuts thefoundations and extends outwardly therefore to protect the foundations100 from climatic factor such as frost.

Referring to FIGS. 26 and 27 in another embodiment, a wall 200 includesa foam layer 201 formed using foam panels 202, 204 and 206 oriented suchthat seams between the panels 202, 204 and 206 are substantiallyparallel to upper and lower edges 208 and 210. As previously stated,orienting the panels 202, 204 and 206 with seams perpendicular to forcesincurred when lifting prevents cracking of the concrete layer or wythe.As previously stated the foam layer 201 is typically a nominal six oreight inches thick. However, other thicknesses of the foam layer 201 arealso contemplated.

A plurality of spaced apart channels 212 are cut into the foam layer 201in a manner similar as described with respect to the channels 58 and 60.The plurality of spaced apart channels 212 have a dovetail cross-sectionand extend from the upper edge 208 to the lower edge 210 and rebar ispositioned, as required by engineering specification, in the channels212 as previously described. Alternatively, concrete fibers can beutilized instead of rebar. As illustrated, the channels 212 are spaced adistance D1 approximately thirty six inches to forty eight inches aparton center. However, any distance D1 is within the scope of the presentdisclosure. While a dovetail cross-section is illustrated, the channelcan have other cross-sectional configurations. Rebar is positionedwithin the channels 212 as described for walls 12 and 22.

The foam layer 201 includes spaced apart grooves 214 that aresubstantially square or rectangular in configuration. The spaced apartgrooves 214 extend into the foam layer 201 a distance less than thedistance the channels 212 extend into the foam panel 201. The grooves214 interrupt a bonding surface 203 of the foam panel 201 which resultsin better bonding between the foam panel 201 and a concrete layer orwythe when placed. As illustrated, the grooves 214 are spaced apart adistance D2 between about twelve inches and about 24 inches. However,any distance D2 is within the scope of the present disclosure. Also,while the grooves 214 are disclosed and illustrated herein, the grooves214 are optional.

A left bracket 220 is secured to the foam layer 201 proximate a leftedge 205 and along a length of the left edge 205 and a right bracket 222is attached to the foam layer 201 proximate a right edge 207 and along alength of the right edge 207. The brackets 220 and 222 are configured towithstand forces imparted by placed concrete, provide a screed surfacefor leveling the placed concrete and provide a finished surface forsecuring adjacent walls together. The bracket 220 provides a finishedsurface or edge to the panel or wall surface.

A bottom bracket 224 is secured to the foam layer 210 proximate thebottom edge 210 and a top bracket 226 is secured to the foam layer 201proximate the top edge 208 where both brackets 224 and 226 extend alonga length of the respective edge. The brackets 224 and 226 are configuredto withstand forces imparted by placed concrete, provide a screedsurface for leveling the placed concrete and provide a finished surfacefor securing adjacent walls together.

Each bracket 220, 222, 224 and 226 includes a top edge that issubstantially even where a distance from the top edge of the bracket220, 222, 224 and 226 to the bonding surface 203 of the foam layer 201defines a thickness of a wythe 230 of concrete that forms the wall 200.

When placed, the concrete fills the channels 212 and grooves 214 to formpilasters 232, 234 where the dovetailed pilasters 232 are utilized forstructural integrity and the smaller pilasters 234 are provideadditional bonding between the wythe 230 and the foam layer 201. Asdescribed in more detail below each bracket 220, 222, 224 and 226 has aflat member that extends in a direction substantially parallel to thebonding surface 203 of the foam layer 201 which provides as surface toscreed the wythe 203. The use of the brackets 220, 222, 224 and 226allows the wall to be formed with a finished outer surface of the wythe230 and finished edges and therefore the wall 200 will require minimal,if any finishing work prior to installation.

Each bracket 220, 222, 224 and 226 are utilized to different purposes.Referring to FIGS. 28 and 28A, the bracket 226 is utilized to form theupper edge of the wall 200 while retaining lifting mechanisms 240thereto such that when the concrete wythe 230 is placed the liftingmechanisms 240 are securely encased in the wythe 230 and providesufficient support to enable a cable or chain to be attached thereto fora lift from a horizontal portion to a substantially vertical positionand onto foundation 100.

The bracket 226 includes a bottom portion 242 that is substantially flatand is configured to abut the bonding surface 203 of the foam layer. Anangled tang 244 extends from one edge of the bottom portion 242. Theangled tang 244 is configured to be positioned within a slot foam layer201 where the slot has substantially the same angle. The angle is acuteand is in the range of 20 degrees and about 60 degrees. A typical angleis about 30 degrees. The engagement of the tang 244 with the slotprevents movement toward the upper end 208 of the foam layer when theconcrete is placed. The bottom portion 242 can be secured to the bondingsurface 203 with a layer of adhesive.

The bracket 226 includes a wall 246 that extends from another edge ofthe bottom portion 242. The wall 246 has a height H from the bottomportion 242 that defines the thickness of the wythe 230. A screedportion 248 extends from the wall 246 wherein the screed portion 248 issubstantially parallel to the bottom portion 242 such that the placedconcrete can be screeded using the brackets 220, 222, 224 and 226.

The wall 246 includes spaced apart apertures 250 that are configured toallow access to the lifting mechanism 240 when encased within the wythe230. Prior to placing the concrete, an end cap 252 having a similarperimeter to that of the aperture is positioned through the aperture.The end cap 252 has a slot 254 that separates end cap halves 256, 258that are secured together with a living hinge 260. The slot 254 isspread apart and a top portion 262 of the lifting mechanism 240 havingat least one aperture 264 therein is positioned within the slot 254. Theend cap halves 256, 258 are forced together to frictionally secure theend cap 252 about the top portion 262 of the lifting mechanism 240.

The end cap 252 is then secured within the aperture 250 in the wall 246such that the lifting mechanism 240 is retained in a selected position.The lifting mechanism 240 includes a main portion 266 between the topportion 262 and the bottom portion 268. The bottom portion includesarcuate members 270, 272 that function as an anchor to prevent thelifting mechanism 240 from being pulled through the top portion of thewall 200 as the wall 200 is lifted. While arcuate anchor members 270,272 are illustrated, other types of anchor configurations can beutilized.

The end cap 252 can also be utilized in different applications such as,but not limited to, providing access to a tightening mechanism securedto cables within the concrete wythe such that the concrete can be posttensioned. Post tensioning the concrete allows the structure to beutilized in different applications, such as, but not limited to a floorpanel.

The lifting mechanism 240 is typically of a monolithic constructionwhere a material of construction is steel. However, other material ofconstruction besides steel is contemplated for the lifting mechanism240.

Once the concrete is placed and cured, the end cap 240, having a lowsurface energy, is removed to provide access to a void in the wythe 230which provides access to the aperture 264. Cables or chains can then besecured to spaced apart lifting mechanism 240 to lift the wall 200.

Prior to placing the concrete, spaced apart braces 281 are secured inspaced apart slots 282 in the bottom portion 242 and spaced apart slots284 in the wall 246. An area of the slots 282 and 284 are minimized toprevent concrete from flowing therethrough. The braces 281 include a “T”shaped end 286 that is wider than the slot 284 wherein one portion ofthe “T” shaped end 286 is position through the slot 284 followed by theother portion. A typical slot 284 is a coin slot opening, which preventsconcrete from flowing through the slot. The portions of the “T” shapedend 286 prevent the end 286 from sliding through the slot 284. The brace281 includes a hook shaped end 288 that is configured to engage the slot282 in the bottom portion 242.

With the “T” shaped end 286 positioned through the slot 284, manualforce is placed onto the brace 281 which causes the bracket 240 to flexand cause the wall 246 towards the bottom portion 242. The hook shapedend 288 is then positioned the slot 228 and when the force is releasedthe brace 281 is in tension, which provides a counteracting force to theforce of the placed concrete on the wall 246. As such, the wall 246 isretained in the selected position when the concrete wythe 230 is placed.

The brace 281 includes a tab 283 that extends outwardly therefrom. Thetab 283 allows rebar or other materials to be secured to the brace. Therebar can be utilized to retain the lifting mechanisms 240 in theselected portion.

Referring to FIGS. 29 and 29A, a similar bracket 300 to that of bracket240 is illustrated. The bracket 300 includes a bottom portion 302,angled tang 304, substantially vertical wall 306 and a screed portion308 that is substantially parallel to the bottom portion 302. The bottomportion 302 includes slot 310, similar to slot 280 in the bracket 240,and slot 312, similar to slot 282 in the wall 246, such that the samebrace 281 can be utilized. The slot 312 is located within a channel 313,that is angled from the wall 313. The channel 313 defines corners intowhich an adhesive placed when walls are secured together. The corners inthe adhesive created by the channel 313 prevent air and moisturepenetration. A similar process is used to install and secure the bracket300 to the foam layer 201 relative to the bracket 240. The bracket 240is typically used on the bottom portion of the wall 202, but can be usedon any edge of the wall 200.

The left and right edges 205 and 207 are typically at an angle such thatwhen adjacent walls are secured together, a single seam is formed.Typically the angle of the structure is determined and bisected suchthat the walls 200 have abutting surfaces having the same lengths anddimensions. For instance when two walls are joined to form a 90 degreecorner, a bracket 310 having a wall 314 having a 135 degree anglerelative to the bottom portion 312 is utilized as illustrated in FIGS.30 and 30A. The bracket includes an angled tang 316 and a screed portion318, as previously described.

The bracket 310 includes spaced apart slots 320 in the bottom portion312 and spaced apart slots 322 in the wall 314. Braces 324 having asimilar configuration to the brace 281 are utilized wherein the ends ofthe brace 324 are installed in the slots 320 and 322.

FIG. 31 is a schematic of two walls 330 and 332 joined at a 45 degreeangle using the bracket 310. Each wall 330, 332 is constructed asdescribe with respect to wall 200 and includes the foam layer 334 andthe concrete wythe 336. Each wall 330, 332 includes the bracket 310 andthe foam layer 334 is at the same angle as that of the wall 314.

While a 90 corner and a 135 degree angled corners are illustrated, othercommon angles for the walls of the wall relative to the bottom portionof the brackets include an angle of 22.5 degrees for a bay treatment, 90degrees for butted walls and 135 degrees for outer bay treatments.Further, a bracket with a forty five degree angled wall can be used forinside corners.

The wall 314 of the bracket 310 is located between about one eighth toone quarter of an inch form the foam surface 334 on the wall 330 and thewall 314 of the bracket 310 is positioned between about one eighth of aninch to about one half of an inch from the angled foam surface 334 onthe wall 332 to provide a gap between the brackets 310. A typical gap isbetween about one quarter of an inch and about one half of an inch.

An adhesive layer is positioned in the void between the angled foamsurface 334 and the wall 314 to substantially fill the void. A typicaladhesive is a pre-compressed joint sealant. One such pre-compressedjoint sealant is sold under the WillSeal® trade designation by WillSeallocated in Hudson, N.H. However any suitable adhesive or sealant iswithin the scope of the present application. As the walls 330, 332 arepositioned proximate each other, the adhesive securely joins the twoedges to secure the walls 330, 332 together.

Referring to FIG. 32 , two walls 360, 362 are joined to form a 135degree angle using the brackets 340. The walls 360, 362 include foamlayers 364, 366 and concrete wythes 368, 370 along with brackets 340.The bracket 340 is secured flush with the surface of the foam layer 366of the wall 362 while the bracket 340 is secured a distance from thesurface of the foam layer 362 of the wall 360 where the distance istypically between about one eighth of an inch and about one half of aninch. An adhesive layer 372 is positioned in the void between the walls344 and when the walls 360, 362 are positioned next to each other, theadhesive layer 372 secures the walls 360, 362 together.

Referring to FIG. 33 , another embodiment of a wall 380 is illustratedand is constructed as described with respect to the wall 200. Forpurposes of clarity, only top bracket is illustrated where aperture 264within lifting mechanism 240 is illustrated. The wall 380 has a modifiedfoam layer 382 relative to the foam layer 201 of the wall 200. The wythe384 is similar that of the wythe 230.

The foam layer 382 includes an upper portion 386 that extends above asurface 388 that is substantially flush or even with the wall 246 of thebracket. The upper portion 386 extends a length of the foam layer 283and has spaced apart channels 390 having a bottom surface 392 locatedabove the surface 388. The channels are configured to accept a rafterbeam or ceiling beam and are spaced apart to accept the rafter beam orceiling beam per the building specification. An insert 390, typicallymetal with a “U” shaped channel, can be installed to provide additionalstrength to the foam layer 382, although the insert is not required.Preforming the foam layer 382 with the channels 390 decreases the amountof time and labor required to build a structure as the rafter beams orceiling beams can be adhered within the channels. 390. Optionally, acomplementary piece of foam (not shown) with similarly spaced apartchannels can be installed on the surface 388 once the wall 380 is in theraised position to extend a length of the channels 390 and provide morestability to the rafter beam or ceiling beam secured within the channel390.

A method 400 of constructing a building is illustrated in FIG. 34 . Themethod includes step 402 of clearing a location for the building,excavating the necessary soil to the proper finished grade, digging inthe pier in selected locations about a footprint or perimeter of thebuilding and to locate foundations and insulation. In step 404 piers arepositioned into the ground at selected elevations and locations wherefoundation about such that ends of adjacent foundations are supported bythe pier. It is contemplated that each pier having an upper surface thatis at substantially the same level such that the foundation will belevel. An exemplary pier is a bell shaped pier however other styles ofpiers are also contemplated. After the piers are created in the soil,the interior can be vacuumed to remove loose soil and the concrete isplaced into the interior of the foundation.

At step 406 the foundations as previously described herein arepositioned on the soil such that the soil supports the foundation alongits length and end portions are supported by the piers. Once installed,the foundations provide a perimeter or footprint of the building.

At step 408, the preformed composite foam and concrete walls 12, 22, 200or 380 are raised and set onto the respective foundation and securedtogether at the respective side edges with adhesive. The walls 12, 22,200 or 380 are shimmed at the interface with the foundation whennecessary to cause the upper surfaces of joined walls to besubstantially even. A bottom portion of the wall is then secured to thefoundation. A top surface of the adjacent walls can be joined togetherwith any suitable bracket.

At step 410, insulating layers are posited about the foundation andoutwardly from the foundation. The insulating layer prevents frost andother environmental factors from affecting the foundation. At step 412,soil is back filled over the foundation, insulating layer and the bottomportion of the wall.

At step 414, rafters and or ceiling beams are installed. The rafter orceiling beams are typically installed with walls 380 having the channels390 for accepting the beams or rafters. However, the ceiling beamsand/or rafters can be secured to a top beam as illustrated with walls 12and 22. The ceiling beams and rafters can optionally be constructed fromLSL.

At step 416, another story or the roof is installed and shingled. Apreferred roofing system is a metal roof manufactured by Gerard RoofingTechnologies located in Brea, Calif. At step 418, foam is positionedbetween the rafters or ceiling joints and a ceiling material isinstalled.

At step 419, an insulation layer is installed within the footprint ofthe building. A typical thickness of insulation is between about 4 and10 inches, depending upon local building codes.

At step 420, rebar is positioned above the insulating layer and ends ofthe rebar are tied to the wythe in the exterior wall. Optionally, aradiant heating system can be installed and then a slab concrete isplaced within the foot print of the building.

At step 424, interior walls and utilities are installed. At step 426,the interior of the building is finished.

In another embodiment, an area of land is leveled in preparation for abuilding to be constructed. Underground services including, but notlimited to, sewer and water and optionally electrical are installed andthe associated trenches are then compacted to a required density.Referring to FIG. 35 , batter boards 500 are set for a perimeter 502 ofthe building and a nominal one inch to a nominal two inches of sand isplaced on the leveled soil within the space defined by the batter boardsand compacted to a building code for the area.

The soil is excavated and graded for a selected distance beyond theperimeter. The soil is excavated and graded to support a foam layer thatprovides frost protection to the foundation.

Holes 504 for piers are then drilled in locations where two foundationsmeet. Loose soil is removed from the holes 504 and the base of the holeis compacted. Once the holes 504 are drilled and the soil is removed,foam portions of the foundations are positioned about a perimeter of thestructure.

Referring to FIG. 36 , abutting ends 512, 514 of the foundations 508,510 are configured to have an angled surface that abut each other. Forinstance in FIG. 36 a right angled corner is illustrated where theabutting ends have forty five degree surfaces. Depending upon the angleof the corner, the angle is bisected to determine the angle of theabutting edges of the foundations.

Referring to FIGS. 36 and 37 , rebar 516 is positioned in a top channel518 of the foundations 508, 510. Rebar also bridges the two abutting512, 514 surfaces and from the top channel 518 and into the holes 502for the piers. Once the entire perimeter is completed, the foundations508, 510 form a continuous top channel 518 and end slots 520 in the foamprovide an opening to the drilled holes 502.

Concrete is then placed into the top channel 518 and fills the holes 502to form the piers for the foundations 508, 510. Because the concrete isplaced into the foundations 508, 510 and into the holes 502 to form thepiers when cured, the concrete is of a monolithic construction thatprovides additional strength to the structure.

Once the concrete has cured, the walls can be raised and secured to thefoundations as previously described. Alternatively, the walls can beformed using an alternative construction.

Referring to FIG. 38 , in the alternative construction, a wall 530 canbe formed by providing a first panel 532 having a desired thickness,typically between two inches and six inches in thickness. The firstpanel 532 is constructed as previously described where the seams betweenthe first panels is substantially perpendicular or normal to stressesincurred during a lift, such as a tilt lift. The first panel 532 hassubstantially flat top and bottom surfaces 531 and 532 and optionallyholes are cut through the thickness of the panel for window and doors aspreviously described.

Brackets 540, 542, 544 and 546 are secured about the perimeter of thefirst panel 532 with an adhesive. The brackets 540, 542, 544 and 546 aresimilar to the brackets 220, 222, 224 and 226 previously disclosed.However because an adhesive is utilized, the tang is not required toretain the brackets 540, 542, 544 and 546 to the first panel 532. Toinstall the braces of the brackets 540, 542, 544 and 546, a groove iscut into the top surface 531 to provide sufficient space to secure thebrace to the bottom member as previously discussed. Because a minimalamount of material is removed, the first panel has improved structuralstrength relative to the panel having the angled slots for accepting theangled tang.

Channels 535 that define the pilasters are formed by securing a secondlayer 534 having spaced apart portions to the first layer 532 with anadhesive. As previously disclosed, the second portions form dovetailedchannels for forming the concrete pilasters. However, the portions ofthe second layer can provide any desired configurations.

With the braces and the portions of the second layer secured to thefirst layer, the concrete is placed onto the exposed surfaces of thefirst and second layers. The braces are utilized as a screed surface aspreviously disclosed.

The bottom surface 533 of the first layer 532 includes a fire resistantlayer of material. A typical material of construction is Sold under theDENSILITE trade designation. However, the present disclosure is notlimited to this material.

The walls 530 are secured together as previously described. Once theexterior walls are in place on the concrete in the foundation, ceilingbeams, trusses and/or rafters are secured within spaced apart slots 552in the top edge of the first panel 532. Inserts may optionally besecured within the slots between the first panel 532 and the ceilingbeams and/or rafters to provide increased structural integrity.

Once the ceiling beams, trusses and/or rafters are installed, a foamlayer is positioned between the ceiling beams and/or rafters. The foamlayers provide insulation and can also reduce the transmission of soundbetween stories of the structure. If required, a sheeting can beinstalled above the ceiling beams, trusses and/or rafters.

In some instances, electric wiring is placed on an upper surface of theceiling beams and or stringers of the rafters. One or more through boresis cut into the foam layer for lighting and a wireless light isinstalled. One or more wireless switches are installed into a wallwherein the one or more switches are typically battery powered whichreduces the installation costs associated with the installation ofwiring. The wireless system is more energy efficient relative to typicalinstallations.

Referring to FIGS. 36 and 39 , foam portions 560 of the foundations 508,510 include through bores 562 that allow drainage tubing 564 to beinstalled in a pattern, typically a grid pattern. Referring to FIG. 40 ,a material 566 is placed over the drainage tubing wherein the materialallows moisture and gases such as radon to travel therethrough and intothe drainage tubing such that the moisture is removed from thestructure. A typical material of construction is ¾ minus or 1 inch minusaggregate. The material is compacted to a required code and protects thedrainage tubing or tile.

With the drainage tubes 564 installed, a layer of insulating foam 568 ispositioned on the material 566 and radiant heat heating tubes 570 areinstalled and secured to the layer of foam 568. Rebar chairs 572 areinstalled on the foam layer 570 and at least one grid of rebar 574 isinstalled on the chairs 572. Rebar 574 is also positioned into the foamportions 560 of the foundations 508, 510 around the perimeter of thestructure. Concrete 578 is then placed on the foam layer 568 and coversthe radiant heating tubes 570 and the rebar 574, 576 wherein the rebar576 extending into the foam portions 568 of the foundations 508, 510ties the concrete slab 578 to the foundations 508, 510. A typicalthickness of the concrete slab 578 is between four and ten inches andmore typically between six and eight inches, however the thickness willbe controlled by engineering specifications for the structure.

In some embodiments, a channel is cut into the inner surface of somewalls. The channels provide a conduit to place electrical wiring intothe structure. In some embodiments, the channels are cut proximate abottom surface such that a floor board can be installed to cover thechannel, which decreases construction costs. However, the channels forthe wiring can be located anywhere within the inner surface of thewalls.

In some instances, additional interior walls or hung cabinets aredesired for a structure. To provide sufficient structural integrity forthe interior walls or hung cabinetry, a channel can be cut into theinner surface of the foam of a size sufficient to secure a board thereinwith an adhesive. The board can then be utilized as a mounting materialfor the wall or the cabinetry. However, because the board does notextend to the concrete, there is no thermal bridge from the outdoorenvironment to the inside environment. Alternatively, the board can beanchored to the exterior concrete wythe.

A foam layer is installed about the perimeter of the foundations toprotect the foundations from frost. Soil is then backfilled to a desiredgrade and covers the foam layer.

Referring to FIG. 41 , another building method is illustrated that issimilar to that as disclosed with respect to FIG. 34 . The method 600includes cleaning, excavating and fine grading the building site at step602. At step 604 piers are located and dug and foam forms are placed inposition to define a perimeter of the structure. At step 606, concreteis placed in the foam forms and piers to create a monolithic foundation.Once the foundation is set, the method includes steps 608-626 that aresimilar or the same as disclosed with respect to steps 408-426 tocomplete the construction.

Examples

The present disclosure is more particularly described in the followingexamples that are intended as illustrations only, since numerousmodifications and variations within the scope of the present disclosurewill be apparent to those skilled in the art.

A simulation of the energy performance of the disclosed walls 12, 22,200 and 380 along with a roof with the Gerard metal roof was conductedby DAREnergy Consulting located in Sacramento, Calif. using theCBECC-Res energy compliance software to determine the thermal efficiencyof the disclosed structure. The fixed assumptions for the simulationincluded a structure 48 feet by 24 feet with an assumption that qualityinsulation installation (QII) was used to account for the lack of airgaps in the windows, doors and between the joints of the walls andbecause the disclosed structure has substantially no thermal bridging.An assumption was made that there were 4.4 changes of air per hour.

The construction of the walls was assumed to have a three inch wythe ofconcrete and variable thickness foam (EPS with an R value of 4.8/inch).The outer walls were covered with a layer of stucco and the inner layerswere covered with gypsum board.

An assumption was made that the structure had 10% glass coverage withthe long walls having 44.8 squre feet of windows and the short wallshaving 22.4 square feet of windows. The windows were assumed to have aU-factor of 0.32 and a solar heat gain coefficient of 0.34.

The floor was a slab of concrete covered with tile. An insulating layerof R-10 insulation was installed outside of the structure a maximumdistance of four feet.

As previously discussed the roof was a metal roof with cool roofproperties for zones 12 and 14, and was assigned a 0.27 reflectance and0.90 emittance. An R-5 above deck insulation was assumed and variableamounts of EPS foam was inserted between the rafter beams located on a24″ spacing. The roof assumed a 1 inch continuous layer of insulationand optionally a radiant barrier (such as foil) installed at the top ofthe attic to block solar gains from the roof.

The space conditioning assumed a combined hydronic and 90% boiler withno cooling. The wall thickness and insulating variables were simulatedin different climate zones and include the following results forCalifornia Climate Zone 16 with and without a radiant barrier on theroof in Tables 1, California Climate Zone 14 with and without a radiantbarrier on the roof, California Climate Zone 12 with and without aradiant barrier on the roof. Wall insulation thickness, and roofinsulation was varied in the simulations. The results are as follows.

TABLE 1 Cold (California Climate Zone 16) Wall Insulation RoofInsulation Energy Design Variable Roofing Variable Variable RatingPerformance 8 inches (R38) Gerard Metal Roof, 10 inches EPS (R48) 88.3956.6-58.8% no radiant barrier 6 inches (R31) -same- R48 + R5 89.4755.1-57.5% 5.5 inches (R26) -same- R48 + R5 90.58 53.6-56.1% 4.5 inches(R22) -same- R48 + R5 91.80 51.9-54.5% 3.5 inches (R17) -same- R48 + R594.04 48.9-51.7% 2 inches (R10) -same- R48 + R5 100.21 40.5-43.9% 8inches (R38) -same- 8 inches EPS (R38) 89.24 55.4-58.0% 6 inches (R31)-same- R38 + R5 90.33 53.9-56.6% 5.5 inches (R26) -same- R38 + R5 71.4252.5-55.2% 4.5 inches (R22) -same- R38 + R5 92.63 50.8-53.7% 3.5 inches(R17) -same- R38 + R5 94.85 47.8-50.9% 2 inches (R10) -same- R38 + R5101.00 39.5-42.9% 8 inches (R38) -same- 6 inches EPS (R29) 90.4053.8-56.8% 6 inches (R31) -same- R29 + R5 91.47 52.4-55.5% 5.5 inches(R26) -same- R29 + R5 92.57 50.9-54.1% 4.5 inches (R22) -same- R29 + R593.75 49.3-52.5% 3.5 inches (R17) -same- R29 + R5 95.94 46.3-49.6% 2inches (R10) -same- R29 + R5 102.07 38.0-41.5%

TABLE 2 High Desert (continued) Wall Insulation Roof Insulation EnergyDesign Variable Roofing Variable Variable Rating Performance 8 inches(R38) GerardCool Roof, 10 inches EPS (R48) 97.79 43.6-49.2% w/radiantbarrier 6 inches (R31) -same- R48 + R5 98.68 42.3-48.1% 5.5 inches (R26)-same- R48 + R5 99.70 40.9-46.9% 4.5 inches (R22) -same- R48 + R5 100.8339.3-45.3% 3.5 inches (R17) -same- R48 + R5 102.94 36.4-42.6% 2 inches(R10) -same- R48 + R5 108.93 28.2-35.2% 8 inches (R38) -same- 8 inchesEPS (R38) 98.32 42.8-48.5% 6 inches (R31) -same- R38 + R5 99.3041.4-47.3% 5.5 inches (R26) -same- R38 + R5 100.33 40.0-45.9% 4.5 inches(R22) -same- R38 + R5 101.46 38.5-44.3% 3.5 inches (R17) -same- R38 + R5103.57 35.6-41.8% 2 inches (R10) -same- R38 + R5 109.59 27.3-34.3% 8inches (R38) -same- 6 inches EPS (R29) 99.17 41.6-47.3% 6 inches (R31)-same- R29 + R5 100.16 40.2-46.0% 5.5 inches (R26) -same- R29 + R5101.19 38.8-44.6% 4.5 inches (R22) -same- R29 + R5 102.33 37.3-43.3% 3.5inches (R17) -same- R29 + R5 104.44 34.4-40.7% 2 inches (R10) -same-R29 + R5 110.47 26.1-33.1%

TABLE 3 High Desert (California Climate Zone 14) Wall Insulation RoofInsulation Energy Design Variable Roofing Variable Variable RatingPerformance 8 inches (R38) Gerard Cool Roof, no 10 inches EPS (R48)98.36 42.7-48.6% radiant barrier 6 inches (R31) -same- R48 + R5 99.2641.5-47.4% 5.5 inches (R26) -same- R48 + R5 100.29 40.1-45.9% 4.5 inches(R22) -same- R48 + R5 101.40 38.5-44.6% 3.5 inches (R17) -same- R48 + R5103.53 35.6-41.9% 2 inches (R10) -same- R48 + R5 109.54 27.4-34.4% 8inches (R38) -same- 8 inches EPS (R38) 98.99 41.8-47.6% 6 inches (R31)-same- R38 + R5 99.98 40.5-46.3% 5.5 inches (R26) -same- R38 + R5 101.0039.1-45.1% 4.5 inches (R22) -same- R38 + R5 102.14 37.5-43.4% 3.5 inches(R17) -same- R38 + R5 104.26 34.6-41.0% 2 inches (R10) -same- R38 + R5110.27 26.4-33.4% 8 inches (R38) -same- 6 inches EPS (R29) 99.9640.5-46.1% 6 inches (R31) -same- R29 + R5 100.96 39.1-45.0% 5.5 inches(R26) -same- R29 + R5 101.99 37.7-43.5% 4.5 inches (R22) -same- R29 + R5103.13 36.2-42.2% 3.5 inches (R17) -same- R29 + R5 105.25 33.3-39.6% 2inches (R10) -same- R29 + R5 111.27 25.0-32.0%

TABLE 4 Hot & Cold (California Climate Zone 12) Wall Insulation RoofInsulation Energy Design Variable Roofing Variable Variable RatingPerformance 8 inches (R38) Gerard Cool Roof, no 10 inches EPS (R48)89.77 42.9-49.4% radiant barrier 6 inches (R31) -same- R48 + R5 90.5141.5-48.2% 5.5 inches (R26) -same- R48 + R5 91.31 40.0-46.9% 4.5 inches(R22) -same- R48 + R5 92.12 38.5-45.5% 3.5 inches (R17) -same- R48 + R593.68 35.6-42.9% 2 inches (R10) -same- R48 + R5 98.22 27.2-35.2% 8inches (R38) -same- 8 inches EPS (R38) 90.40 41.7-48.3% 6 inches (R31)-same- R38 + R5 91.11 40.4-47.0% 5.5 inches (R26) -same- R38 + R5 91.8938.9-45.8% 4.5 inches (R22) -same- R38 + R5 92.71 37.4-44.4% 3.5 inches(R17) -same- R38 + R5 94.32 34.4-41.7% 2 inches (R10) -same- R38 + R598.84 26.0-34.0% 8 inches (R38) -same- 6 inches EPS (R29) 91.1940.2-46.8% 6 inches (R31) -same- R29 + R5 91.96 38.8-45.5% 5.5 inches(R26) -same- R29 + R5 92.69 37.4-44.3% 4.5 inches (R22) -same- R29 + R593.54 35.9-42.9% 3.5 inches (R17) -same- R29 + R5 95.15 32.9-40.1% 2inches (R10) -same- R29 + R5 99.69 24.5-32.4%

TABLE 5 Hot & Cold (continued) Wall Insulation Roof Insulation EnergyDesign Variable Roofing Variable Variable Rating Performance 8 inches(R38) Gerard Cool Roof, 10 inches EPS (R48) 89.28 43.8-50.2% w/radiantbarrier 6 inches (R31) -same- R48 + R5 90.03 42.4-49.0% 5.5 inches (R26)-same- R48 + R5 90.82 40.9-47.7% 4.5 inches (R22) -same- R48 + R5 91.6339.4-46.3% 3.5 inches (R17) -same- R48 + R5 93.19 36.5-43.7% 2 inches(R10) -same- R48 + R5 97.73 28.1-36.0% 8 inches (R38) -same- 8 inchesEPS (R38) 89.81 42.8-49.2% 6 inches (R31) -same- R38 + R5 90.5741.4-48.0% 5.5 inches (R26) -same- R38 + R5 91.33 40.0-46.7% 4.5 inches(R22) -same- R38 + R5 92.20 38.3-45.3% 3.5 inches (R17) -same- R38 + R593.73 35.5-42.7% 2 inches (R10) -same- R38 + R5 98.27 27.1-35.0% 8inches (R38) -same- 6 inches EPS (R29) 90.53 41.4-47.8% 6 inches (R31)-same- R29 + R5 91.31 40.0-46.6% 5.5 inches (R26) -same- R29 + R5 92.0538.6-45.4% 4.5 inches (R22) -same- R29 + R5 92.89 25.7-33.6% 3.5 inches(R17) -same- R29 + R5 94.48 34.1-41.3% 2 inches (R10) -same- R29 + R599.02 37.1-44.0%

The Energy Design Rating reflects the annual energy consumptionincluding lighting, domestic appliances, and electronics not included inthe California Title 24 performance. The Performance is a percentage ofthe level above a building that complies with California's EnergyEfficiency Standards (Title 24, Part 6) for space conditioning and waterheating. The lower range of performance is an East/West frontorientation of the building and the higher range is for a North/Southfront orientation of the building.

The results of the simulation indicate a significant increase in energyefficiency relative to California Energy Efficiency Standards. Thesimulations surprisingly indicated at least a forty percent increase inperformance independent of the climate zone and whether or not a radiantbarrier was considered. Also, comparing the simulations with the radiantbarrier to simulations without the radiant barrier resulted in a slightincrease in simulated energy efficiency.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above ashas been determined by the courts. Rather, the specific features andacts described above are disclosed as example forms of implementing theclaims.

1. A composite foam and concrete wall comprising; a foam layer having atop surface, a bottom surface, a left wall surface and a right wallsurface wherein the foam layer comprises at least two foam panels thatdefine a seam that is substantially parallel to the top surface and thebottom surface; and a concrete layer secured to a surface of the foamlayer.
 2. The composite foam and concrete wall of claim 1 and whereinthe foam layer comprises: a plurality of spaced apart channels extendingfrom proximate the bottom surface to proximate the top surface; and aplurality of pilasters within the channels and extending from theconcrete layer.
 3. The composite foam and concrete wall of claim 2 andwherein the plurality of spaced apart channels and the plurality ofpilasters comprise a dovetail cross-section.
 4. The composite foam andconcrete wall of claim 1 and further comprising: a left channelextending into the foam layer along the left wall surface; a rightchannel extending into the foam along the right wall surface; and a topchannel extending into the foam along the top surface.
 5. The compositefoam and concrete wall of claim 4 and further comprising: a leftconcrete pilaster extending from the concrete layer and positionedwithin the left channel; a right concrete pilaster extending from theconcrete layer and positioned within the right channel; and a topconcrete pilaster extending from the concrete layer and positionedwithin the top channel.
 6. The composite foam and concrete wall of claim1 and further comprising a top plate secured to a top surface of theconcrete layer from the left surface to the right surface.
 7. Thecomposite foam and concrete wall of claim 1 and further comprising:spaced apart lifting mechanisms positioned through the top plate whereinthe spaced apart lifting mechanism are configured to engage a liftingmechanism such that the wall can be raised to a substantially verticalor standing position.
 8. The composite foam and concrete wall of claim 1and wherein the foam layer has a nominal thickness in the range of about3 inches to about 10 inches.
 9. The composite foam and concrete wall ofclaim 1 and wherein the concrete layer has a nominal thickness in therange of about 2 inches to about 6 inches such that the wall is astructural, load bearing wall.
 10. A method of constructing a compositefoam and concrete wall, the method comprising: positioning a pluralityof foam panels proximate each other to form a foam layer of a selectedheight and width; forming a plurality of spaced apart channels in thefoam layer extending from proximate a bottom end to proximate a top end;positioning rebar within the spaced apart channels; positioning a formabout a perimeter of the foam layer wherein the form extends above anupper edge of the foam layer a selected distance; and placing concreteon the foam panel and within the form to form a concrete layer with aplurality of pilasters extending into the foam layer and within theplurality of spaced apart channels.
 11. The method of claim 10 andwherein forming the plurality of spaced apart channels comprises formingdovetail cross-sectional channels and wherein the placed concrete formsdovetail cross-sectional pilasters.
 12. The method of claim 10 andwherein positioning a form about a perimeter of the foam layercomprises: cutting an angled slot about the perimeter of the foam layer;and positioning brackets about the perimeter wherein each bracketcomprises: a bottom portion positioned on the foam layer; a angled tangextending from the bottom portion and positioned within the angled slot;a wall extend from the bottom portion wherein a thickness the concretelayer is defined by a height of the wall; and a screed portionsubstantially parallel to the bottom portion wherein the brackets areretained to the concrete layer and forms a finished surface.
 13. Themethod of claim 10 and wherein positioning a form about a perimeter ofthe foam layer comprises: positioning boards about the perimeter of thefoam layer wherein the board at the top end comprises a top plate;securing the boards together; and after the concrete layer has cured,removing the form from the wall wherein the top plate is retained to thewall.
 14. The method of claim 10 and further comprising: cutting an areafor a window from the foam layer; and positioning a window frame withinthe cut out area wherein the cut out area is larger than the windowframe such that when the concrete is placed the concrete encases thewindow frame.
 15. The method of claim 10 and further comprising: cuttingan area for a door from the foam layer; and positioning a door framewithin the cut out area wherein the cut out area is larger than the doorframe such that when the concrete is placed the concrete encases thedoor frame.
 16. The method of claim 10 and further comprising: forming aplurality of spaced apart grooves within the foam layer and between thespaced apart channels wherein the spaced apart grooves have a smallercross-sectional area and depth relative to the cross-sectional area ofthe spaced apart channels wherein when the concrete is placed thegrooves are filled with concrete.
 17. A composite foam and concrete wallcomprising; a foam layer having a top surface, a bottom surface, a leftwall surface and a right wall surface wherein the foam layer comprisesat least two foam panels that define a seam that is substantiallyparallel to the top surface and the bottom surface; a form secured to atop surface of the foam layer and extending from a perimeter of the foamlayer; and a concrete layer placed onto a surface of the foam layerwherein the form is retained to the foam layer and provides a finishedsurface to the concrete layer.
 18. The composite foam and concrete wallof claim 17 and wherein the foam layer comprises: a plurality of spacedapart channels extending from proximate the bottom surface to proximatethe top surface; and a plurality of pilasters within the channels andextending from the concrete layer.
 19. The composite foam and concretewall of claim 18 and wherein the plurality of spaced apart channels andthe plurality of pilasters comprise a dovetail cross-section.
 20. Thecomposite foam and concrete wall of claim 17 and wherein the foam layerhas a nominal thickness in the range of about 3 inches to about 10inches. 21-22. (canceled)